Assembly of Crab Cavities HOMS field antenna in
Assembly of Crab Cavities HOMS & field antenna in SM 18 clean room Eric Montesinos, Sebastien Calvo, Emile Grospelier, Antoine Boucherie, Frida Eriksson, on behalf of BE-RF-PM section members With inputs from Ilan Ben Zvi (BNL) Thomas Jones (STFC) Karl Schirm, Alick Macpherson, Giovanna Vandoni, Mathieu Therasse, Gabriel Pechaud, Max Gourragne, Sauro Bizzaglia (BE-RF-SFR team) Ofelia Capatina, Pierre Minginette and Teddy Capelli (EN-MME-EDM)
Preamble All presented proposals have been made with inputs of experts that we wish to thank Ilan Ben Zvi – BNL Thomas Jones – STFC Karl Schirm, Alick Macpherson, Giovanna Vandoni, Gabriel Pechaud, Max Gourragne, Sauro Bizzaglia – BE-RF-SRF SM 18 clean room Ofelia Capatina, Pierre Minginette, Teddy Capelli – EN-MME-EDM The proposals match with the existing structure of the cleanrooms and any material will be validated by the BE-RF-SRF team eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 2
Preamble The Fundamental Power Coupler team BE-RF-PM will be trained to assist the BE-RF-SFR team during the assembly of the FPC Romuald Terry did participate in the LHC couplers mounting onto LHC cavities in SM 18 cleanroom facilities, and is asked to help the SRF team when needed Sebastien Calvo did participate in the SPL coupler mounting in CEA l’Orme Les Meurisiers clean room facilities, and in the ESRF couplers in ESRF clean room facilities Eight other PM team members will be trained in the coming weeks in order to provide help if requested Romuald & Seb At any stage, PM team will be ‘assisting’ SRF experienced experts that will always lead the tasks in clean room eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 3
Global Workflow All parts come from the chemistry (build. 102) degreased and individually bagged in plastic bag All soldered or EBW parts will always follow a ''clean'' process (packaging and handling with gloves) All sets will be re-washed manually before entering baldaquin/ cleanroom Colours define provider groups eric. montesinos@cern. ch sebastien. calvo@cern. ch BE/RF/PM BE/RF/SRF Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland EN/MME 4
What to be assembled ? 2 x 3 HOMS (High Order Modes Suppressors couplers) 2 x 1 RF Field Antenna Length: 205 mm Mass: 3. 5 kg eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland Length: 239 mm Mass: 0. 5 kg 5
HOMS & RF Field Antenna 1 RF Field Antenna 3 x HOMS eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 6
Assembly of devices eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 7
Main devices Description Area Delivery of parts packed by the Chemists experts in plastic bag 1 Blow with pure air 1 Go to clean room ISO 5 2 Blow with pure air and open the plastic bag 2 2 Time Day 1 HOMS body eric. montesinos@cern. ch sebastien. calvo@cern. ch 1 HOMS feedthrough Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland RF Field Antenna 8
Accessories Description Area Delivery of accessories, nuts, bolts, washers and copper seals. . . packed by the Chemists experts in plastic bag 1 Blow with pure air 1 Go to clean room ISO 5 2 Blow with pure air and open the plastic bag 2 Vacuum support for HOMs Vacuum support for antenna eric. montesinos@cern. ch sebastien. calvo@cern. ch 2 Time For HOMS 1 For Field Antenna Day 1 DN 16 valve Positioning system design on going Accura 25 qualified (Mathieu) & Stainless Steel Sliding parts as far as possible form the aperture System still to be tested and qualified Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland Copper RF & Vac seal Screws A 4. 100 M 6 x 45 Studs A 4. 100 M 6 x 25 Washers 6 x 12 Bolts A 4. 100 M 6 9
Particles counting Description Area Time Dry with pure air 2 Day 1 Keep under laminar flux 2 Night 1 Blow and particles counting 2 Put all devices in the SAS 3 eric. montesinos@cern. ch sebastien. calvo@cern. ch 3 2 SAS 3 Day 2 Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 10
Moving to ISO 4 Description Area Move all components to be assembled from the SAS to ISO 4 area 4 Store the other components in storage ISO 5 area 5 Inner volume of the HOMS body support is much larger than needed to avoid any contact eric. montesinos@cern. ch sebastien. calvo@cern. ch 5 3 4 Time Day 3 SAS 3 5 4 Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 11
HOMS assembly Description Area Manually assemble the HOMS, seals and feedthrough 4 Tighten until no gap between flanges, cross and circle 4 Store in ISO 5 5 5 Time Day 3 4 2 x 3 2 nd 1 st Support clamped on the table eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 12
Field Antenna assembly Description Area Manually assemble the Field Antenna 4 Tighten until no gap between flanges, cross and circle 4 Store in ISO 5 5 Time 5 4 2 Day 3 Support clamped on the table eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 13
Vacuum leak detection Description Area Leak detection to verify a leak rate < 1 x 10 -10 mbar l/s 5 Store all devices in ISO 5 5 Time 5 2 Day 4 All supports clamped on the table eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 14
Assembly on CRAB cavity eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 15
Back to ISO 4 Description Move all needed devices to ISO 4 Insert ISO 4 filtered Nitrogen (N 2) in the cavity ATM + 0. 2 bars with a pressure reducer and an output flow through the port of around 20 l/min 5 Area Time 4 2 1 4 Day 1 4 N 2 flux eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 16
Assembly flowchart Description Area Mount the centring device Remove the blank flange Assemble the device (see next slides) 4 Mount washers and screws 5 Tighten until no gap between flanges, cross and circle 5 Leak detection to verify a leak rate < 1 x 10 -10 mbar l/s 5 eric. montesinos@cern. ch sebastien. calvo@cern. ch Time 5 4 2 1 Day 1 Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 17
HOMS positioning system 3. 5 kg Positioning system design on going Accura 25 qualified (Mathieu) & Stainless Steel Sliding parts as far as possible form the aperture System still to be tested and qualified eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 18
HOMS positioning system If the flip option is provided by the Lifting Device, will be from the top Positioning system design on going Accura 25 qualified (Mathieu) & Stainless Steel Sliding parts as far as possible form the aperture System still to be tested and qualified eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 19
Field Antenna positioning system From the side under laminar flux 1 kg eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 20
Fine angle positioning system eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 21
Final assembly eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 22
HOMS assembly tests Before we mount these assemblies in clean room, we will do some pre-mounting in our mechanical laboratory in order to test all our tools and in order to train the colleagues Tooling for HOMS clean room assembly Bat 864 -R-D 15 Workshop HOMS 3 D printed for assembly test purpose Simulation of the cavity eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 23
Field Antenna assembly tests Before we mount these assemblies in clean room, we will do some pre-mounting in our mechanical laboratory in order to test all our tools and in order to train the colleagues Tooling for Field Antenna clean room assembly Bat 864 -R-D 15 Workshop Field antenna 3 D printed for assembly test purpose Simulation of the cavity eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 24
Planning Training with 3 D prints in 864 eric. montesinos@cern. ch sebastien. calvo@cern. ch HOMS & Antenna Assembly HOMS & Antenna assembly on cavity 4 days 1 Day Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 25
ANNEXES eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 26
Total mounting tolerances Seal RF - DN 40 After mounting tolerances hoped: Off-center tolerances DN 63 = mini -0. 05 mm maxi 0. 25 mm Ø Seal tolerance DN 63 : Ø 82. 4 +/-0. 05 Ø Flange tolerance DN 63 : Ø 82. 5 0. 1/0 (x 2) Total angles tolerances mini -0. 15 mm maxi 0. 1 mm ~0. 15° Ø Ungasing slot tolerance : 1. 5 +/-0. 1 (x 2) Ø Angle positioning tool tolerance : 1. 4 0/-0. 05 Asked positioning for FPC assembly: Axials tolerances +/- 1 mm Angles tolerances +/- 1° what we can have with the accumulated tolerances max: Axials tolerances +0. 25 mm/-0. 05 mm Angles tolerances +/- 0. 15° eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 27
Positioning system design on going Accura 25 qualified (Mathieu) and Stainless Steel Sliding parts as far as possible form the aperture System still to be tested and qualified eric. montesinos@cern. ch sebastien. calvo@cern. ch Review of clean room procedures for the HL-LHC Crab Cavity Program, HOMS, 12 -13 October 2016, CERN, Geneva, Switzerland 28
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